Well, got the car home today and tested the spare motor. It is indeed 80ppr on the encoder. Did a little bit of playing and still pritty much the same. ie hits current limit when trying to accelerate. This gets me thinking about a possible hardware problem with my Enova board. What would happen if t...

This is probably nuts but what if the encoder bearing data sheet is counting 80 pulses over 2 channels and its really a 40ppr per channel output?

I guess it's possible but I hope not. Going to get the car home tomorrow so hopefully will get to the bottom of it.

Found this interesting data sheet.

I had set fweak high to try and reduce motor current. Almost like the motor is not making any back emf.

One other thing of note is I think this is a delta connected motor if that makes any difference?

I went down to the car today and changed to the correct 80 ppr setting for the encoder. Sadly however this didn't fix the problem although the motor does run much smoother. The main problem seems to be very high motor amps from the start. With the second parameter set, basically changed fslipmin to ...

Merry Christmas everyone

No I'm not sure:) I just measured the pulses on the scope but could easily have made an error. That could very well be the answer. Thanks very much:)

For those interested I have released V4 of the small drive unit hardware on Github :
https://github.com/damienmaguire/Tesla-Front-Drive-Unit

Now has onboard WiFi.

It uses an AB encoder bearing with 75ppr. I did have a noise issue on the speed signal but it is now clean. I think Johannes has a good point about the slip. I'll give this a try.

Can't seem to add picture of the motor plate. Error parsing server response.

My new Ansaldo motor in the E39 hates me. Finally got the cooling done today and decided to go try some tuning. Not very successfully. Can't get more than about 30 amps of battery current into the inverter but motor current very high. Speed signal is clean and current sensors are reading correctly. ...